Rigid Piston Retrofit for a Diaphragm Flush Valve

ABSTRACT

A rigid piston assembly for use in a conventional flush valve includes a rigid piston configured to fixedly engage within the valve body. The present invention is also directed to a flush valve for a plumbing fixture as well as a method of retrofitting a rigid piston into a diaphragm flush valve body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/947,286, filed Nov. 20, 2015, which is a continuation of U.S. patentapplication Ser. No. 13/832,758, filed Mar. 15, 2013, now U.S. Pat. No.9,222,584, which claims the benefit of U.S. Provisional PatentApplication No. 61/636,174 filed on Apr. 20, 2012, the entiredisclosures of each of which are hereby incorporated herein by referencein their entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates generally to flush valves and, inparticular, to a rigid piston for use in a flush valve.

Description of Related Art

Valves are used throughout many fluid transfer systems and in variousapplications, such as in the transfer and control of water conduitsystems, and, in particular, in connection with plumbing fixtures inboth residential and commercial settings. For example, flush valves aretypically used for control and operation of toilets, urinals, and thelike, such that when a user actuates a handle, water flows through theflush valve into a basin portion and out the drain.

A common type of flush valve is a diaphragm flush valve. Such adiaphragm flush valve is disclosed in U.S. Pat. No. 4,327,891 to Allenet al., herein incorporated by reference. The Allen patent discloses theuse of a diaphragm in a flush valve, where the diaphragm is made ofmolded rubber and serves to effectuate the flow of water from a waterinlet, through the valve, and to a water outlet. Further, the Allenpatent sets forth various components and sub-components of aconventional flush valve.

Such diaphragm flush valves have several drawbacks. For example, therelatively small by-pass orifice positioned in the diaphragm can becomeclogged with debris, which prevents water from flowing into an upperchamber located in the flush valve. This causes the flush valve toremain open, resulting in constant water flow. In addition, the flushingcycle of the diaphragm flush valve takes approximately seven seconds tocomplete, depending upon the flow rates and pressure of the waterentering the valve, due to the design of the diaphragm of the flushvalve. Since an upper chamber fills slowly, the valve is slowly“shutting off”. Therefore, a significant amount of water is wastedthrough the trap and sewer line during the sealing process of the valve.Yet another drawback is that conventional diaphragm flush valves areimpacted at water pressures below 35 psi, since sealing of the valvebased on the water pressure against the diaphragm is difficult with suchlower water pressure. A need, therefore, exists for a valve replacementelement that can effectively be retrofitted into a flush valve that doesnot have the drawbacks associated with conventional diaphragm flushvalves. A further need exists for a flush valve having improved sealingfeatures.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, a rigidpiston assembly is used as a replacement element in a flush valve havinga valve body with a fluid inlet, a fluid outlet, an outer cover, and ahandle member. The rigid piston assembly includes a rigid piston with acentral opening and a by-pass orifice. The rigid piston is mountedwithin the valve body and is adapted to move axially in the direction ofthe flow of water from the fluid inlet to the fluid outlet. The rigidpiston can further include guide members that maintain the alignment ofthe rigid piston within the valve during operation as well as a flowring that gauges the amount of water to be flushed during operation.

A relief valve can be positioned through the central opening of therigid piston. The relief valve includes an auxiliary valve and a shaftextending from the auxiliary valve. The relief valve can also include asleeve surrounding the shaft that is adapted to move along the shaft. Aseal ring can be positioned between the relief valve and the rigidpiston.

A top closure may be connected to the valve body at an end opposite thefluid outlet. The top closure can include an internal cylindrical capand the outer cover of the flush valve. In another embodiment, the topclosure can be a one-piece cylindrical cover. In yet another embodiment,the top closure can include a cylindrical member and a locking ring. Thetop closure can be made of a plastic or metal.

A piston seal having a by-pass orifice can be fixedly engaged to therigid piston and sealingly engaged to the valve body near an entrance ofthe fluid outlet. The piston seal can have an annular skirt that isadapted to extend out toward the top closure and form a seal with thetop closure. The rigid piston assembly can also include a retainingring. The retaining ring can have a by-pass orifice and can be adaptedto fixedly engage with the piston seal. The retaining ring can include aplurality of channels that are smaller in diameter than the by-passorifice of the retaining ring.

A by-pass device having a body with a first end, a second end, and apassageway located within the body can be placed through the by-passorifices of the rigid piston, the piston seal, and the retaining ring,thereby establishing fluid communication between the fluid inlet and anupper chamber formed between the rigid piston and the top closure. Whenthe upper chamber is relieved of pressure, fluid from the fluid inletforces the rigid piston to axially move in a direction opposite thefluid outlet permitting fluid flow through the fluid outlet.Alternatively, the retaining ring is smaller in size and does notcontain a by-pass orifice. In this embodiment, a central opening of theretaining ring can be adapted to fixedly engage directly to the by-passdevice.

The rigid piston assembly can further include a sealing component thatis placed into the valve body forming a seal between the top closure andthe valve body. The sealing component can be an O-ring.

In accordance with another embodiment of the present invention, a methodof retrofitting a rigid piston into a flush valve having a diaphragmassembly generally includes removing the outer cover from the valvebody, removing the diaphragm valve assembly from the valve body,inserting a rigid piston into the valve body, incorporating a reliefvalve into the rigid piston, and attaching a top closure to the valvebody at an end opposite the fluid outlet. The rigid piston includes apiston seal attached to a portion of the rigid piston and a by-passdevice positioned inside by-pass orifices located in the rigid pistonand the piston seal. The rigid piston can also include a retaining ringattached to the piston seal. The retaining ring can have a by-passorifice and the by-pass device can also be adapted to fit inside theby-pass orifice of the retaining ring. Alternatively, the retaining ringis smaller in size and does not contain a by-pass orifice. In thisembodiment, a central opening of the retaining ring can be adapted tofixedly engage directly to the by-pass device.

The rigid piston is adapted to move axially in the direction of the flowof water from the fluid inlet to the fluid outlet. The method canfurther include placing a seal ring between the relief valve and therigid piston, and placing a sealing component between the top closureand valve body.

In accordance with yet another embodiment of the present invention, aflush valve for a plumbing fixture includes a fluid inlet in fluidcommunication with a fluid source, a fluid outlet in fluid communicationwith a plumbing fixture, a top closure positioned at an end opposite thefluid outlet, and a piston valve for regulating fluid flow between thefluid inlet and the fluid outlet. The piston valve includes a rigidpiston with a central opening and a by-pass orifice. The rigid piston isadapted to move axially in the direction of the flow of water from thefluid inlet to the fluid outlet. The rigid piston can further includeguide members that maintain the alignment of the rigid piston within thevalve during operation as well as a flow ring that gauges the amount ofwater to be flushed during operation.

A relief valve is positioned through the central opening of the rigidpiston. The relief valve includes an auxiliary valve and a shaftextending from the auxiliary valve. The relief valve can also include asleeve surrounding the shaft that is adapted to move about the shaft. Aseal ring is positioned between the relief valve and the rigid piston.

The top closure can include an internal cylindrical cap and the outercover of the flush valve. Alternatively, the top closure can be aone-piece cylindrical cover. In yet another embodiment, the top closurecan include a cylindrical member and a locking ring.

A piston seal having a by-pass orifice is fixedly engaged to the rigidpiston and sealingly engaged to the valve body near an entrance of thefluid outlet. The piston seal can have an annular skirt that is adaptedto extend out toward the top closure and form a seal with the topclosure. The flush valve can also include a retaining ring having aby-pass orifice and can be fixedly engaged to the piston seal. Theretaining ring can include a plurality of channels that are smaller indiameter than the by-pass orifice of the retaining ring.

A by-pass device having a body with a first end, a second end, and apassageway located within the body is positioned inside the by-passorifices of the rigid piston, the piston seal, and the retaining ring.Alternatively, the retaining ring is smaller in size and does notcontain a by-pass orifice. In this embodiment, a central opening of theretaining ring can be adapted to fixedly engage directly to the by-passdevice. The flush valve can also include a sealing component that formsa seal between the top closure and the valve body. The sealing componentcan be an O-ring.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional elevational view of an assembled diaphragmflush valve according to the prior art.

FIG. 2 is an exploded perspective view of the diaphragm flush valveaccording to FIG. 1.

FIG. 3A is a cross-sectional elevational view of a flush valve in anon-activated state according to the present invention.

FIG. 3B is a cross-sectional elevational view of the flush valve of FIG.3A in an activated state according to the present invention.

FIG. 3C is a cross-sectional elevational view of the flush valve of FIG.3A during a flushing event according to the present invention.

FIG. 3D is a cross-sectional elevational view of the flush valve of FIG.3A during a resealing event according to the present invention.

FIG. 4 is an exploded perspective view of the flush valve of FIG. 3Aaccording to the present invention.

FIG. 5 is a cross-sectional assembled elevational view of the flushvalve of FIG. 4 according to the present invention.

FIG. 6A is an exploded perspective view of a flush valve according toanother embodiment of the present invention.

FIG. 6B is an exploded cross-sectional view of the flush valve of FIG.6A according to the present invention.

FIG. 7 is an exploded perspective view of a flush valve according to yetanother embodiment of the present invention.

FIG. 8 is a cross-sectional bottom view of the flush valve of FIG. 7taken along line 8-8 according to the present invention.

FIG. 9 is a top view of a retaining ring according to the presentinvention.

FIG. 10 is a cross-sectional elevational view of a by-pass deviceaccording to the present invention.

FIG. 11 is a cross-sectional elevation view of a by-pass device with aretaining ring according to another embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of the description hereinafter, spatial orientation terms,if used, shall relate to the referenced embodiment as it is oriented inthe accompanying drawing figures or otherwise described in the followingdescription. However, it is to be understood that the embodimentsdescribed hereinafter may assume many alternative variations andembodiments. It is also to be understood that the specific devicesillustrated in the accompanying figures and described herein are simplyexemplary and should not be considered as limiting.

As shown in FIGS. 1-2, a conventional flush valve 2 has a general hollowvalve body 10 which includes a fluid inlet 12, a fluid outlet 14, and ahandle coupling connection 16. The top of the valve body 10 is closed byan outer cover 18 and an inner cover 20. The inlet portion of the valveis separated from the outlet portion by an outlet bore 22 which isattached to the inside of the valve body 10. A main valve seat 24 isformed on the top of the outlet bore 22.

The valve is actuated by an operating handle 26 which is fastened to thevalve body 10 by means of a coupling nut 28. The handle 26 is connectedto a plunger 30 which extends to the interior portion of the valve body10. The plunger 30 is guided and supported by a bushing 32 and restoredby a spring 34. A rubber sealing cap or packing 36 is snapped on the endof bushing 32 and prevents leakage outward from the handle opening.

The main valve seat 24 is normally closed by a flexible rubber diaphragm38. The flexible rubber diaphragm 38 extends across the valve body 10and defines an upper chamber 40. The flexible rubber diaphragm 38includes a by-pass hole 42 which provides fluid communication betweenthe inlet side of the valve and the upper chamber 40. A filter 44 may beprovided thereover to prevent clogging of the by-pass hole 42.

The flexible rubber diaphragm 38 is attached at its outer edge to thevalve body 10. The outer cover 18 clamps the diaphragm 38 to the valvebody 10. The center of the flexible rubber diaphragm 38 has an openingwhich allows fluid communication between the upper chamber 40 and thefluid outlet 14. A relief valve shown generally at 46 is attached to theflexible rubber diaphragm 38 and normally closes the opening at thecenter of the flexible rubber diaphragm 38. The relief valve 46 includesa guide portion 48 having wings 49. The wings 49 fit closely against theinside diameter of the outlet bore 22. The guide 48 also has a lip 50.The lip 50 supports a collar 52. The relief valve 46 includes a clampingmember 54 which is threadably engaged with the guide portion 48. Theclamping member 54 clamps the inner edge of the flexible rubberdiaphragm 38 between the clamping member 54 and the collar 52 to form aseal. The clamping member 54 has a hole in the middle which is normallyclosed by an auxiliary valve member 56. This auxiliary member 56 isconnected to a depending stem 58 which extends to a point opposite theactuating plunger 30.

Referring specifically to FIG. 2, a central throat 23 is first placedinto the valve body 10. A guide ring 70 is placed around a top portionof the central throat 23, and a flow ring 72 is placed on top of theguide ring 70. The flexible rubber diaphragm 38 is then placed into thevalve body 10. A by-pass hole 42 is positioned in the flexible rubberdiaphragm 38 and a molded disc 74 is placed onto the flexible rubberdiaphragm 38. The relief valve 46 is placed through openings located inthe center of the molded disc 74 and diaphragm 38. An inner cover 20 isplaced over the diaphragm assembly and an outer cover 18 is placed ontop of the inner cover 20. As discussed in detail above, flush valvesincorporating a flexible rubber diaphragm 38 have numerous drawbacks.Accordingly, the present invention is directed to a rigid piston 310, asshown in FIG. 4, for use in a conventional flush valve body 10.

As shown in FIGS. 4-5, the present invention includes a rigid piston 310having a disc shaped member 306 defining a central opening therein andan elongated hollow member 308 that extends from the disc shaped member306 of the rigid piston 310. The rigid piston 310 sits directly withinthe hollow valve body 10 providing a mechanism for regulating water flowthrough the valve body 10.

When placed into the valve body 10, the disc shaped member 306 of therigid piston 310 sits on top of a central valve seat 124 of the outletbore 22 and the elongated hollow member 308 extends down into the outletbore 22. The disc shaped member 306 extends outward from the centralseat 124 of the outlet bore 22 to an inside annular shoulder 116 of thevalve body 10 creating a lower chamber 158 and an upper chamber 160, asshown in FIG. 3A. The lower chamber 158, located below the disc shapedmember 306 of the rigid piston 310 near the fluid inlet 12, is definedbetween the rigid piston 310, outlet bore 22, and valve body 10. Theupper chamber 160, located above the disc shaped member 306 of the rigidpiston 310, is defined between the rigid piston 310, the valve body 10,and a top closure that is attached to the valve body 10 at an endopposite the fluid outlet 14.

The rigid piston 310 can have a scallop shaped flow ring 314 formaintaining a constant water flow area, such as shown in FIG. 8. Theflow ring 314 can be attached to the outer surface of the elongatedhollow member 308 of the rigid piston 310. During flushing, water flowsaround the flow ring 314 as it enters the outlet bore 22. The flow ring314 helps regulate the flow of water during flushing, which allows for aconsistent turbulent flow of water during flushing when the rigid piston310 is incorporated into the valve body 10. A consistent turbulent flowof water through the throat of a toilet helps ensure proper flushingwith a sufficient amount of water. The flow ring 314 also ensures a highvelocity of flush which allows for a quicker and more efficient flush.

Guide members 316 can also be attached to the elongated hollow member308 of the rigid piston 310 (see FIG. 4). The guide members 316 extenddown the length of the elongated hollow member 308 of the rigid piston310. When the rigid piston 310 is placed into the valve body 10, theguide members 316 abut the inside wall of the outlet bore 22 securingthe elongated hollow member 308 of the rigid piston 310 within the valvebody 10. The guide members 316 ride along the inside wall of the outletbore 22 as the rigid piston 310 moves during operation. This preventsthe rigid piston 310 from shifting during operation, thereby maintainingproper alignment of the rigid piston 310 within the valve body 10 at alltimes. In one embodiment, the flow ring 314 is attached to the guidemembers 316.

Referring to FIG. 4, a piston seal 140 can be attached to the rigidpiston 310. The piston seal 140 can be made of an elastomeric materialsuch as rubber. The piston seal 140 is configured to fixedly engage withthe rigid piston 310. For example, an undersurface 311 of the discshaped member 306 of the rigid piston 310 can be adapted to fixedlyengage with a sealing surface 141 of the piston seal 140. In anon-limiting embodiment, as shown in FIG. 4, the undersurface 311 of thedisc shaped member 306 of the rigid piston 310 may define cavities (notshown) and the piston seal 140 may include corresponding projections126, such as barbed projections, that can be placed into the cavities ofthe rigid piston 310, thereby securing the piston seal 140 to the rigidpiston 310. The piston seal 140 can further have an annular skirt 128that completely surrounds the outer edge of the piston seal 140.

The piston seal 140 is sized and shaped to engage and form a seal withthe valve body 10. In one embodiment, the piston seal 140 is designed toengage and form a first seal with the central valve seat 124 of theoutlet bore 22 and a second seal with a top closure that is attached tothe valve body 10 after the rigid piston 310 is inserted into the valvebody 10. For instance, once the piston seal 140 is attached to the rigidpiston 310, the rigid piston 310 and piston seal 140 can be placed intothe valve body 10. A central sealing ring 143 extending from the pistonseal 140 can be placed into the outlet bore 22 of the valve body 10.This engagement forms a first seal around the central valve seat 124 ofthe outlet bore 22. This helps prevent water from leaking into the fluidoutlet 14 from the fluid inlet 12.

The annular skirt 128 of the piston seal 140 can engage the inside of atop closure that is attached to the valve body 10 at an end opposite thefluid outlet 14. For example, the annular skirt 128 may include asealing edge 129 located at the bottom end of the annular skirt 128 asshown in FIG. 4. As water flows through the fluid inlet 12 into thelower chamber 158 (see FIG. 3A), water pushes up on the piston seal 140.The pressure forces the annular skirt 128 surrounding the piston seal140 to extend out toward the top closure attached to the valve body 10.The sealing edge 129 of the annular skirt 128 contacts the inside of thetop closure and forms a seal between the piston seal 140 and the topclosure. This second sealing engagement prevents water in the lowerchamber 158 from leaking around the outer portion of the rigid piston310 into the upper chamber 160.

The dual sealing arrangement described above makes it possible to formseparate and distinct seals at two different areas in a flush valve body10 at the same time with a single piston seal 140. The use of a singlesealing member to form multiple sealing engagements in different areasat the same time, allows for an efficient sealing arrangement in a flushvalve body 10. It also allows for an easy and fast installation process.

Referring again to FIG. 4, the piston assembly can further include aretaining ring 90. As shown in FIG. 4, the retaining ring 90 can beadapted to engage the piston seal 140. For example, in one embodiment,the retaining ring 90 has a plurality of projections 114 that can beplaced into corresponding cavities (not shown) located in the pistonseal 140, thereby securing the retaining ring 90 to the piston seal 140.As shown in FIG. 9, the retaining ring 90 may include a plurality ofchannels 94 that are small in diameter, preventing large debris fromentering the channels 94.

In accordance with one embodiment of the present invention as shown inFIG. 4, a by-pass orifice 312 may be defined in the disc shaped member306 of the rigid piston 310. The piston seal 140 may also include asecond by-pass orifice 142. A by-pass device 300 can be placed throughthe by-pass orifices 312, 142 of the rigid piston 310 and the pistonseal 140. The by-pass device 300 includes a body having a first end 302and a second end 304 (see FIG. 4). The second end 304 of the by-passdevice 300 can be placed through the by-pass orifice 312 defined in therigid piston 310, and the first end 302 of the by-pass device 300 can beplaced through the by-pass orifice 142 defined in the piston seal 140.In certain embodiments, when a retaining ring 90 is used, the first end302 of the by-pass device 300 also can be placed through a by-passorifice 92 defined in the retaining ring 90. Alternatively, theretaining ring 90 can be smaller in size and does not contain a by-passorifice 92. In this embodiment, a central opening of the retaining ring90 can be adapted to fixedly engage directly to the by-pass device 300,as shown in FIG. 11.

As shown in FIG. 10, the by-pass device 300 further contains apassageway 301 formed within the body of the by-pass device 300. Thispassageway 301 connects the lower chamber 158 near the fluid inlet 12 tothe upper chamber 160 located above the rigid piston 310. The passageway301 of the by-pass device 300 is designed so that water can enterthrough at least one opening located near the first end 302 of theby-pass device 300. The water can then flow from the opening(s) locatednear the first end 302, through the passageway 301, and out an openinglocated at the second end 304 of the by-pass device 300. Referenceletter “B” in FIG. 10 illustrates the flow of water from the lowerchamber 158 to the upper chamber 160 by way of the passageway 301 of theby-pass device 300.

During assembly of one embodiment, according to the present invention,the second end 304 of the by-pass device 300 is placed through theby-pass orifice 312 of the rigid piston 310. The piston seal 140 isattached to the rigid piston 310 with the first end 302 of the by-passdevice 300 being placed through the by-pass orifice 142 of the pistonseal 140. Once placed into the valve body 10, the piston seal 140 formsa seal with the central valve seat 124 of the outlet bore 22 and a topclosure that is attached to the valve body 10 after the rigid piston 310is placed into the valve body 10. This prevents water from entering thefluid outlet 14 and the upper chamber 160 as described above. As aresult, water from the fluid inlet 12 can only enter the upper chamber160 through the by-pass device 300.

In one embodiment, a retaining ring 90 is attached to the piston seal140 and the first end 302 of the by-pass device 300 is placed throughthe by-pass orifice 92 of the retaining ring 90. In this embodiment,water cannot enter directly through the by-pass orifice 92 in theretaining ring 90. Instead, water flows through the channels 94 locatedin the retaining ring 90 and into the opening(s) located near the firstend 302 of the by-pass device 300, which then flows out the second end304 of the by-pass device 300 and into the upper chamber 160 (see FIG.10).

As shown in FIG. 9, the channels 94 located in the retaining ring 90 aresmaller in diameter than the by-pass orifice 92 of the retaining ring90. This filters out large debris, thereby preventing clogging of thepassageway 301 of the by-pass device 300. If smaller debris does clogthe channels 94 directly surrounding the by-pass orifice 92 of theretaining ring 90, water can enter through other channels (not shown)positioned in different locations of the retaining ring 90.

Alternatively, in certain embodiments, the retaining ring 90 can besmaller in size and does not contain a by-pass orifice 92. In thisembodiment, a central opening of the retaining ring 90 can be adapted tofixedly engage directly to the by-pass device 300 (see FIG. 11).

Referring to FIG. 4, the present invention can further include a reliefvalve 130 that closes the opening in the center of the rigid piston 310.The relief valve 130 includes an auxiliary valve member 134 having anoperating stem 132 that is configured to extend through the elongatedhollow member 308 of the rigid piston 310 so that the operating stem 132is positioned adjacent a handle member, such as an actuating rod 200,when placed into the valve body 10. A seal 340, such as a gasket, can bepositioned on top of the rigid piston 310 before the relief valve 130 isincorporated into the rigid piston 310. The seal 340 prevents unwantedwater from leaking around the relief valve 130 through the opening atthe center of the rigid piston 310.

The relief valve 130 can have a sleeve 136, as shown in FIG. 3A, thatslides up and down the operating stem 132. The sleeve 136 operates toshut off the valve when the actuating rod 200 is held down for a longperiod of time. If the actuating rod 200 is held down for a certainperiod of time, the sleeve 136 will slide up the operating stem 132 andsit on top of the actuating rod 200. The next flush cannot be actuateduntil the sleeve 136 is back to its normal position.

As mentioned above, a top closure is placed onto the valve body 10 afterthe rigid piston 310 is installed in order to cover the top of the flushvalve body 10. In one embodiment, referring to FIG. 4, the top closureincludes an internal cylindrical cap 120 and the outer cover 18previously used with the diaphragm flush valve. The cylindrical cap 120is placed into the valve body 10 next to the rigid piston 310. The cap120 can be made of any rigid material including various types ofplastics and metals. In addition, the surface of the cap 120 containsthe required lubricity to easily slide into the valve body 10. Onceinserted into the valve body 10, the cylindrical cap 120 further securesthe piston 310 in place and functions as a mechanism limiting themovement of the piston 310 to a consistently steady axial motion withinthe valve body 10.

A sealing component 380, such as an O-ring or gasket, can be positionedinto the valve body 10 next to the rigid piston 310. When the cap 120 isinserted into the valve body 10, pressure is applied to the sealingcomponent 380 contained therein, thereby forming a tight seal betweenthe valve body 10 and the cylindrical cap 120.

The outer cover 18 previously used with the diaphragm flush valve isplaced over the cylindrical cap 120. The outer cover 18 attaches to thecylindrical cap 120 and the outer surface of the valve body 10. Onceattached to the valve body 10, the outer cover 18 continually exertsforce onto the cylindrical cap 120 retaining the cap 120 inside thevalve body 10. When a sealing component 380 is placed inside the valvebody 10, the outer cover 18 helps supply pressure to form the tight sealbetween the valve body 10 and cylindrical cap 120.

In another embodiment shown in FIGS. 6A-6B, the top closure includes aone-piece cylindrical cover 400. In this embodiment, a portion of thecylindrical cover 400 is designed to fit into the valve body 10 tosecure the piston 310 in place and to limit the movement of the rigidpiston 310 to a consistently steady axial motion within the valve body10. The cylindrical cover 400 is also configured to attach to the outersurface of the valve body 10. As with the previous embodiment, a sealingcomponent 380A, such as an O-ring or gasket, can be positioned insidethe valve body 10 to form a tight seal between the cylindrical cover 400and the valve body 10. The cylindrical cover 400 can be made of anyrigid material including various types of plastics and metals. Forinstance, the cylindrical cover 400 can be made of chrome.

In yet another embodiment shown in FIG. 7, the top closure comprises atwo-piece top cover including a cylindrical member 500 and a lockingring 510. A portion of the cylindrical member 500 is designed to fitinto the valve body 10 to secure the rigid piston 310 in place and tolimit the movement of the rigid piston 310 to a consistently steadyaxial motion within the valve body 10. A sealing component 380B, such asan O-ring or gasket, can also be positioned inside the valve body 10 toform a tight seal between the cylindrical member 500 and the valve body10. However, the cylindrical member 500 does not attach to the outersurface of the valve body 10. Rather, the locking ring 510 is attachedto the outer surface of the valve body 10 and the outer surface of thecylindrical member 500 further securing the cylindrical member 500 tothe valve body 10. The locking ring 510 can be designed to attach to anytype of valve body 10. The cylindrical member 500 and locking ring 510can be made of the same material or different materials. For example,both the cylindrical member 500 and locking ring 510 can be made ofchrome.

FIG. 3A shows the piston assembly, according to one embodiment of thepresent invention, incorporated into the valve body 10 while the flushvalve is in a closed steady-state position. The piston seal 140, nowattached to the rigid piston 310, engages the central valve seat 124 ofthe outlet bore 22. Pressure from water flowing through the fluid inlet12 causes the annular skirt 128, as shown in FIG. 4, to extend outwardonto the inside of the top closure, as also shown in FIG. 4, of thevalve body 10. The water flowing into the fluid inlet 12 passes throughthe channels 94 in the retaining ring 90, through the passageway 301 ofthe by-pass device 300, and into the upper chamber 160 (see FIG. 10). Asshown in FIG. 3, the relief valve 130 closes the opening in the centerof the rigid piston 310 preventing water from entering the centralopening. The pressure in the upper chamber 160 forces the piston 310down into the piston seal 140, which forces the piston seal 140 onto thecentral valve seat 124 forming a seal around the outlet bore 22 so thatthere is no fluid communication between the fluid inlet 12 and fluidoutlet 14 channels.

In operation, as shown in FIG. 3B, the actuating rod 200 is movedcausing the actuating rod 200 to contact the sleeve 136 of the operatingstem 132 of the relief valve 130. As the operating stem 132 tilts to oneside, the auxiliary valve member 134 lifts off of the opening located inthe center of the piston 310, thereby relieving the pressure from theupper chamber 160 by allowing water to flow to the outlet 14. Inletwater pressure forces the piston 310 to move axially upwards off of thecentral valve seat 124 in a direction opposite the fluid outlet 14. Theguide members 316 attached to the elongated hollow member 308 of therigid piston 310 ride along the inside wall of the outlet bore 22maintaining proper alignment of the rigid piston 310 as it moves off thecentral valve seat 124.

During flushing, as shown in FIG. 3C, water flows directly from thefluid inlet 12 into the flow ring 314, which gauges the proper amount ofvolume to be flushed. The water then continues to the fluid outlet 14 inthe direction shown by reference letter “A” in FIG. 3C. As the valve isflushing, the water pressure pushing the rigid piston 310 off thecentral valve seat 124 is continuing to act on the annular skirt 128 ofthe piston seal 140. This pressure pushes the annular skirt 128 outtowards the top closure that is attached to the valve body 10. Thismaintains a seal between the lower chamber 158 and upper chamber 160 sothat water can only enter the upper chamber 160 through the by-passdevice 300. As water flows from the inlet 12 into the outlet 14, wateris also flowing through the by-pass device 300 into the upper chamber160. When the water pressure in the upper chamber 160 is greater thanthe inlet 12 water pressure, the rigid piston 310 and piston seal 140are forced back onto the central valve seat 124 in a steady axial motionwith the help of the guide members 316 so that there is no fluidcommunication between the inlet 12 and outlet 14.

As shown in FIG. 3D, if the actuating rod 200 is held down in theactivated position for an extended period time, the sleeve 136 attachedto the operating stem 132 of the relief valve 130 will slide up on topof the actuating rod 200. This will shut the valve off and preventexcessive flushing. The next flush cannot be actuated until the sleeve136 is again positioned next to the actuating rod 200.

The present invention is also directed to a method of retrofitting arigid piston 310 into a flush valve body 10. Referring to FIG. 4, themethod includes removing the outer cover 18 from the diaphragm flushvalve, and then removing the diaphragm valve assembly from the valvebody 10. Next, the rigid piston 310 and piston seal 140 are attached toeach other with the by-pass device 300 placed within by-pass orifices312, 142 defined in the rigid piston 310 and piston seal 140. In oneembodiment, a retaining ring 90 is attached to the piston seal 140 andthe by-pass device 300 is also placed within a by-pass orifice 92defined in the retaining ring 90. Alternatively, the retaining ring 90can be smaller in size and does not contain a by-pass orifice 92. Inthis embodiment, a central opening of the retaining ring 90 can beadapted to fixedly engage directly to the by-pass device 300 (see FIG.11).

The rigid piston 310 is axially mounted into the valve body 10 and ontothe central valve seat 124 of the outlet bore 22. After mounting therigid piston 310 into the valve body 10, the relief valve 130 isincorporated into and through the rigid piston 310. A seal 340 can bepositioned on top of the piston 310 before the relief valve 130 isincorporated into the valve body 10. A top closure is inserted into thevalve body 10 at an end opposite the flow outlet 14. A sealing component380, such as an O-ring, may also be placed into the flush valve body 10.

Accordingly, the present invention, which is directed to a rigid piston310 that can be used in a conventional flush valve body 10, provides amore efficient flush. Because the by-pass orifice 312 is larger and therigid piston 310 moves with a consistently steady axial movement, lesswater is used during the flush cycle. Further still, the presentinvention can easily be retrofitted into a conventional flush valve body10 allowing for a fast and cheap installation process.

While several embodiments of the invention were described in theforegoing detailed description, those skilled in the art may makemodifications and alterations to these embodiments without departingfrom the scope and spirit of the invention. Accordingly, the foregoingdescription is intended to be illustrative rather than restrictive.

The invention claimed is:
 1. A method of retrofitting a rigid pistoninto a flush valve, the flush valve having a valve body with a fluidinlet, a fluid outlet, a diaphragm valve assembly, an outer cover, and ahandle member, the method comprising the steps of: a) removing the outercover from the valve body; b) removing the diaphragm valve assembly fromthe valve body; c) inserting a rigid piston into the valve body, therigid piston comprising a disc shaped member having a central opening,an elongated hollow member that is attached to and extends down from thedisc shaped member, and a piston seal attached directly to at least aportion of the disc shaped member, wherein the rigid piston is adaptedto move axially in the direction of the flow of water from the fluidinlet to the fluid outlet; d) incorporating a relief valve into therigid piston; and e) attaching a top closure to the valve body at an endopposite the fluid outlet, and wherein the piston seal comprises anannular skirt surrounding an outer edge of the piston seal that isadapted to expand out toward the top closure connected to the valve bodyand form a seal with the top closure.
 2. The method according to claim1, wherein the rigid piston is placed on top of a central valve seatsuch that the elongated hollow member extends down into an outlet boreof the flush valve.
 3. The method according to claim 1, wherein theannular skirt extends around an outside perimeter of both the pistonseal and the disc shaped member.
 4. The method according to claim 1,wherein the piston seal comprises a disc shaped body with a centralopening and the annular skirt extends around an outer edge of the discshaped body.
 5. The method according to claim 4, wherein at least aportion of the disc shaped body of the piston seal is attached to atleast a portion of the disc shaped member of the rigid piston.
 6. Themethod according to claim 1, wherein the relief valve comprises anauxiliary valve and an operating stem extending from the auxiliary valvethat is placed into the elongated hollow member of the rigid piston. 7.The method according to claim 6, wherein the rigid piston furthercomprises a seal ring positioned on a top surface of the disc shapedmember around the central opening, and wherein at least a portion of therelief valve is placed onto the seal ring.
 8. The method according toclaim 6, wherein the relief valve further comprises a sleeve surroundingat least a portion the operating stem.
 9. The method according to claim1, wherein the rigid piston further comprises guide members thatmaintain the alignment of the rigid piston within the valve body duringoperation.
 10. The method according to claim 9, wherein the guidemembers extend out from the elongated hollow member.
 11. The methodaccording to claim 1, wherein the rigid piston further comprises a flowring that gauges an amount of water to be flushed during operation. 12.The method according to claim 11, wherein the flow ring is positionedbelow the disc shaped member of the rigid piston.
 13. The methodaccording to claim 12, wherein the flow ring is attached to theelongated hollow member of the rigid piston.
 14. The method according toclaim 13, wherein the flow ring is a scallop shaped flow ring.
 15. Themethod according to claim 1, wherein the piston seal is formed from asingle rubber article.
 16. The method according to claim 1, wherein thedisc shaped member of the rigid piston comprises a by-pass orifice 17.The method according to claim 16, wherein the piston seal comprises aby-pass orifice that is aligned with the by-pass orifice of the discshaped member of the rigid piston.